Fiber placement system and method with modulated laser scan heating

ABSTRACT

A fiber placement system including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a compaction nip region, and a laser heating assembly including a laser that emits a beam of electromagnetic radiation and a scan head defining a scan field, the scan field being aligned with the compaction nip region, wherein the scan head scans the beam within the scan field.

PRIORITY

This application is a divisional of U.S. Ser. No. 14/711,133 filed onMay 13, 2015.

FIELD

This application relates to fiber placement and, more particularly, tolaser-assisted fiber placement.

BACKGROUND

Composite structures are commonly used as high-strength, low-weightmaterials and, therefore, find various applications in the aerospace andautomotive industries. A composite structure includes one or morecomposite layers, wherein each composite layer includes a reinforcementmaterial and a matrix material. The reinforcement material may includefibers. The matrix material may be a polymeric material, such as athermosetting resin or a thermoplastic resin.

Fiber-reinforced composite structures may be manufactured by laying upmultiple layers of fiber tow to form a reinforcement layup. The fibertow generally includes a bundle of fibers (reinforcement material)impregnated with a matrix material. In fiber placement technologies, thefiber tow is generally supplied in strip/tape form from a bulk reel andis pressed onto the underlying layup at a compaction nip using acompaction roller. The fully assembled reinforcement layup is then curedand/or consolidated, as necessary, to from the composite structure.

When the matrix material of the fiber tow is a thermoplastic resin, thelayup process typically requires heating to soften the thermoplasticresin and obtain layer-to-layer consolidation within the reinforcementlayup. Typically, a laser beam (e.g., an infrared laser beam) isprojected toward the compaction nip to heat the fiber tow and/or theunderlying layup during fiber placement. However, laser heating can bedifficult to control, resulting in overheating of the fiber tow and/orthe underlying layup.

Accordingly, those skilled in the art continue with research anddevelopment efforts in the field of laser-assisted fiber placement.

SUMMARY

In an embodiment, disclosed is a method for placing a composite ply on asubstrate. The method may include steps of (1) positioning a compactionroller against the substrate to define a nip therebetween; (2) scanninga beam of electromagnetic radiation proximate the nip; and (3) passingthe composite ply through the nip.

Other embodiments of the disclosed fiber placement system and methodwith modulated laser scan heating will become apparent from thefollowing detailed description, the accompanying drawings and theappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side elevational view of one embodiment of thedisclosed fiber placement system;

FIG. 2 is a schematic representation of the scan head of the laserheating assembly of the fiber placement system of FIG. 1;

FIG. 3 is a machine (y-axis) directional view of the compaction nipregion of the fiber placement system of FIG. 1;

FIGS. 4A-4C are graphical representations of beam power versus time forthe laser heating assembly of the fiber placement system of FIG. 1;

FIG. 5 is a flow diagram depicting one embodiment of the disclosed fiberplacement method;

FIG. 6 is a flow diagram of an aircraft manufacturing and servicemethodology; and

FIG. 7 is a block diagram of an aircraft.

DETAILED DESCRIPTION

Referring to FIG. 1, one embodiment of the disclosed fiber placementsystem, generally designated 10, may include a compaction roller 12, alaser heating assembly 14, and a bulk reel 16 of composite ply 18.Without departing from the scope of the present disclosure, the fiberplacement system 10 may include various additional components, such asone or more guide rollers 20 for guiding the composite ply 18 from thebulk reel 16 to the compaction roller 12 and/or a drive mechanism forurging the compaction roller 12 and the laser heating assembly 14 in thedirection shown by arrow Y.

At this point, those skilled in the art will appreciate that thedisclosed fiber placement system 10 may be associated with an AutomatedFiber Placement (AFP) machine. For example, the compaction roller 12 andthe laser heating assembly 14 of the fiber placement system 10 may be atleast partially housed within the application head of an Automated FiberPlacement machine. The application head of the Automated Fiber Placementmachine may be moveable, such as by way of a robotic arm.

The composition of the composite ply 18 supplied from the bulk reel 16of the disclosed fiber placement system 10 may vary depending onneed/application. In one realization, the composite ply 18 may be afiber-reinforced material that includes a reinforcement material and amatrix material. The reinforcement material may be (or may include)fibers, such as carbon fibers. The fibers may be oriented in a singledirection (e.g., uni-directional) or in two or more directions (e.g.,bi-directional). The matrix material may be (or may include) a polymericmatrix material, such as a thermoplastic resin or, alternatively, athermosetting resin. In another realization, the composite ply 18 may beunreinforced (e.g., a resin-only material).

As one specific, non-limiting example, the composite ply 18 may be athermoplastic tow (or slit tape). The thermoplastic tow may include areinforcement material (e.g., carbon fiber) and a thermoplastic polymermatrix material. Specific examples of thermoplastic polymers that may beused to form a thermoplastic tow suitable for use as the composite ply18 include, without limitation, polyether ether ketone (PEEK), polyetherketone (PEKK), polyphenaline sulfide (PPS), polyethylene, polypropylene,and polystyrene.

The compaction roller 12 of the disclosed fiber placement system 10 maybe rotatable about an axis of rotation A (perpendicular to the page inFIG. 1), and may be positioned against a substrate 22 to define a nip 24between the compaction roller 12 and the surface 26 of the substrate 22.The substrate 22 may be any structure or arrangement of material capableof receiving the composite ply 18 on the surface 26 thereof. As oneexample, the substrate 22 may be a reinforcement layup that includes oneor more previously-applied layers of the composite ply 18. As anotherexample, the substrate 22 may be a composite backing material, such as abacking cloth.

The composite ply 18 may be unwound from the bulk reel 16, may pass overthe guide roller 20, may extend over the compaction roller 12 and,ultimately, may pass through the nip 24. As the composite ply 18 passesthrough the nip 24, the compaction roller 12 may urge the composite ply18 against the surface 26 of the substrate 22. Furthermore, as thecompaction roller 12 moves relative to the substrate 22 (e.g., in thedirection shown by arrow Y), a composite layer 28 may be formed over thesurface 26 of the substrate 22. Multiple layers (similar to compositelayer 28) may be applied to the substrate 22 in such a manner.

The laser heating assembly 14 of the disclosed fiber placement system 10may be positioned to project a beam 30 of electromagnetic radiation intothe compaction nip region 25 proximate (at or near) the nip 24 betweenthe compaction roller 12 and the substrate 22. Therefore, the beam 30may heat a portion of the composite ply 18 and/or a portion of thesubstrate 22 just prior to, or simultaneously with, those portions ofthe composite ply 18 and the substrate 22 passing through the nip 24.When the composite ply 18 and/or the substrate 22 includes athermoplastic material, the heat from the laser heating assembly 14 maysoften the thermoplastic material, thereby rendering it tacky andfacilitating consolidation between the composite ply 18 and thesubstrate 22.

The beam 30 of electromagnetic radiation emitted by the laser heatingassembly 14 has a wavelength. The wavelength of the beam 30 may be adesign consideration. In one expression, the beam 30 may have awavelength ranging from about 0.75 μm to about 1.4 μm (near-infrared(NIR)). In another expression, the beam 30 may have a wavelength rangingfrom about 1.4 μm to about 3 μm (short-wavelength infrared (SWIR)). Inanother expression, the beam 30 may have a wavelength ranging from about3 μm to about 8 μm (mid-wavelength infrared (MWIR)). In anotherexpression, the beam 30 may have a wavelength ranging from about 8 μm toabout 15 μm (long-wavelength infrared (LWIR)). In yet anotherexpression, the beam 30 may have a wavelength ranging from about 15 μmto about 1,000 μm (far-infrared (FIR)).

Still referring to FIG. 1, the laser heating assembly 14 may include ascan head 50, a laser 52, a power source 54, an optical fiber 56, and acontroller 58. The laser heating assembly 14 may include additionalcomponents, such as additional electronic components, additional opticalcomponents and/or additional structural components, without departingfrom the scope of the present disclosure.

The scan head 50 of the laser heating assembly 14 may be positionedrelative to the compaction roller 12 and the substrate 22 to project thebeam 30 proximate the compaction roller 12 and, more specifically, intothe compaction nip region 25 proximate the nip 24 between the compactionroller 12 and the substrate 22. In one expression, the scan head 50 maybe spaced about 3 inches to about 36 inches from the nip 24. In anotherexpression, the scan head 50 may be spaced about 4 inches to about 24inches from the nip 24. In yet another expression, the scan head 50 maybe spaced about 6 inches to about 12 inches from the nip 24.

Referring to FIG. 2, the scan head 50 may include a housing 60, a galvoassembly 62, and an optical element 64. The housing 60 may define aninternal volume 66 and an opening 68 into the internal volume 66. Thegalvo assembly 62 may be positioned in the internal volume 66 of thehousing 60. The optical element 64 may be positioned at least partiallywithin the housing 60, and may be aligned with the opening 68 in thehousing 60.

The galvo assembly 62 of the scan head 50 may include an x-axisgalvanometer device 70 and a y-axis galvanometer device 72. The x-axisgalvanometer device 70 may include a first mirror 74 connected to afirst motor 76 by a first shaft 78. The first motor 76 may rotate thefirst shaft 78 and, thus, the first mirror 74 about a first axis ofrotation R₁. Likewise, the y-axis galvanometer device 72 may include asecond mirror 80 connected to a second motor 82 by a second shaft 84.The second motor 82 may rotate the second shaft 84 and, thus, the secondmirror 80 about a second axis of rotation R₂.

While the galvo assembly 62 of the scan head 50 is shown and describedhaving both x-axis and y-axis galvanometer devices 70, 72, using a galvoassembly 62 with only one galvanometer device will not result in adeparture from the scope of the present disclosure. Furthermore, using agalvo assembly 62 with more than two galvanometer devices will notresult in a departure from the scope of the present disclosure.

The scan head 50 may be optically coupled with the laser 52 by way ofthe optical fiber 56, as shown in FIG. 1. Therefore, as shown in FIG. 2,the scan head 50 may receive the beam 30 emitted by the laser 52, andmay direct the beam 30 to the galvo assembly 62. The galvo assembly 62may facilitate scanning of the beam 30 in the manner dictated by thecontroller 58 (FIG. 1). Specifically, the mirror 80 of the y-axisgalvanometer device 72 may receive the incoming beam 30 and, withcontrolled rotation about the second axis of rotation R₂, the mirror 80may scan the beam 30 along the y-axis. The mirror 74 of the x-axisgalvanometer device 70 may receive the beam 30 reflected by the y-axisgalvanometer device 72 and, with controlled rotation about the firstaxis of rotation R₁, the mirror 74 may scan the beam 30 along thex-axis.

Thus, the galvo assembly 62 may define a two-dimensional scan field 86.When the galvo assembly 62 includes an x-axis galvanometer device 70 anda y-axis galvanometer device 72, the scan field 86 may extend in boththe x-axis direction (the lateral direction) and the y-axis direction(the machine direction), as shown in FIG. 2.

As shown in FIG. 1, the controller 58 may be in communication with thescan head 50. The controller 58 may be any apparatus or system (e.g., amicroprocessor) capable is generating and communicating command signalsto achieve a desired result from a controlled device (e.g., the galvoassembly 62, the power source 54, the laser 52). The command signals maybe based on instructions (e.g., inputs from a user) and/or feedbacksignals. Therefore, referring back to FIG. 2, the controller 58 (FIG. 1)may be in communication with the galvo assembly 62 of the scan head 50to provide motion commands to the motors 76, 82 driving the mirrors 74,80 of the galvanometer devices 70, 72 of the galvo assembly 62.

As shown in FIG. 1, and with reference to FIG. 2, the scan head 50 maybe oriented relative to the compaction roller 12 and the substrate 22such that the scan field 86 defined by the galvo assembly 62 is alignedwith (e.g., superimposed over) the compaction nip region 25 proximatethe nip 24 between the compaction roller 12 and the substrate 22.Therefore, by controlling the galvo assembly 62 (e.g., by controllingthe orientations of the mirrors 74, 80 by way of the associated motors76, 82), the controller 58 may project the beam 30 at any desiredlocation within the compaction nip region 25. With robust control of themirrors 74, 80, the controller 58 may effect high speed scanning of thebeam 30 within the compaction nip region 25.

Thus, the scan head 50 may facilitate scanning (e.g., rastering) of thebeam 30 within the compaction nip region 25 in both the x-axis directionand the y-axis direction. As such, a single scan head 50 may heat theentire compaction nip region 25 without the need for an array of lasersand/or an articulation device that articulates a laser to effectmovement of the associated beam.

Referring again to FIG. 2, the optical element 64 of the scan head 50may be positioned to receive the beam 30 leaving the galvo assembly 62.The optical element 64 may manipulate the beam 30 received from thegalvo assembly 62 and may direct the beam 30 into the compaction nipregion 25.

The optical element 64 may be (or may include) a lens, such as anobjective lens. The beam 30 received by the scan head 50 from theoptical fiber 56 may be a diverging beam. Therefore, when the opticalelement 64 is/includes a lens, the beam 30 may be focused into a spot 90having the desired maximum transverse dimension D (e.g., diameter). Inone expression, the maximum transverse dimension D of the spot 90 formedby the beam 30 may range from about 0.001 inch to about 1 inch. Inanother expression, the maximum transverse dimension D of the spot 90formed by the beam 30 may range from about 0.01 inch to about 0.1 inch.As one specific, non-limiting example, the spot 90 formed by the beam 30may have a diameter D of about 0.05 inch.

In one particular construction, the optical element 64 may be (or mayinclude) a telecentric lens. Those skilled in the art will appreciatethat using a telecentric lens as (or in) the optical element 64 mayyield a spot 90 having a maximum transverse dimension D that does notsubstantially vary within the scan field 86 as a function of distancefrom the scan head 50. Therefore, the spot 90 may be substantiallyuniform, even as the spot 90 is moved throughout the scan field 86.

Referring back to FIG. 1, the controller 58 may control one or moreparameters of the beam 30 that is supplied by the laser 52 and,ultimately, projected into the compaction nip region 25. In oneimplementation, the controller 58 may control the optical power of thebeam 30. In another implementation, the controller 58 may control thepulse frequency of the beam 30. In yet another implementation, thecontroller 58 may control both the optical power of the beam 30 and thepulse frequency of the beam 30. Controlling other beam parameters (e.g.,duty cycle) with the controller 58 is also contemplated.

The laser 52 of the laser heating assembly 14 may be electricallycoupled with the power source 54. For example, the power source 54 maybe a source of alternating electric current. The laser 52 may generatethe beam 30 when it is powered by the power source 54. The beam 30 mayhave an optical power, and the optical power may be a function of theelectrical power supplied by the power source 54. For example, when thelaser 52 is supplied 500 watts, the laser 52 may emit a beam 30 havingfull optical power. However, as the supplied power is reduced, theoptical power is reduced a corresponding amount (a percentage of fullpower).

The controller 58 of the laser heating assembly 14 may be incommunication with the power source 54. Therefore, the controller 58 maycontrol the amount of electrical energy supplied to the laser 52 and,thus, the optical power of the beam 30 emitted by the laser 52, bycontrolling the power source 54.

The controller 58 of the laser heating assembly 14 also may be incommunication with the laser 52 to control actuation of the laser 52and/or the pulse frequency of the beam 30 emitted by the laser 52. Inone implementation, the laser 52 may be a continuous wave (CW) laser,and the controller 58 may modulate the beam 30 emitted by the laser 52to achieve the desired pulse frequency. In another implementation, thelaser 52 may be a pulsed laser, and may emit a beam 30 having thedesired pulse frequency.

The pulse frequency of the beam 30 may be based on, among other possiblefactors, the speed at which the galvo assembly 62 (FIG. 2) of the scanhead 50 scans the beam 30. In one expression, the pulse frequency of thebeam 30 may range from about 0 (continuous beam, no pulse) to 10 kHz. Inanother expression, the pulse frequency of the beam 30 may range fromabout 1 kHz to about 10 kHz. In another expression, the pulse frequencyof the beam 30 may range from about 2 kHz to about 8 kHz. In anotherexpression, the pulse frequency of the beam 30 may range from about 3kHz to about 6 kHz. In yet another expression, the pulse frequency ofthe beam 30 may range from about 1 kHz to about 5 kHz.

Accordingly, the laser heating assembly 14 of the disclosed fiberplacement system 10 may scan a beam 30 within a scan field 86 alignedwith the compaction nip region 25 proximate the nip 24 between thecompaction roller 12 and the substrate 22, while controlling the opticalpower of the beam 30 and/or the pulse frequency of the beam 30. Otherparameters of the beam 30 (e.g., duty cycle) may also be controlledwhile the beam 30 is scanned within the scan field 86. Therefore, thelaser heating assembly 14 may be used to obtain various heating profileswithin the compaction nip region 25.

FIG. 3 illustrates an example heating profile that may be obtained onthe composite ply 18 and the substrate 22 using the laser heatingassembly 14 of the disclosed fiber placement system 10. In the specific,non-limiting example of FIG. 3, the beam 30 (FIGS. 1 and 2) may bescanned by the laser heating assembly 14 to yield multiple scan rows100, 102, 104, 106, 108, 110. Each scan row 100, 102, 104, 106, 108, 110may laterally extend (x-axis) across the scan field 86 (FIG. 2) toproduce a column 112 of scan rows 100, 102, 104, 106, 108, 110 thatextends in the machine (y-axis) direction along the scan field 86. Scanrows 100, 104, 108 may be formed on the surface 26 of the substrate 22within the compaction nip region 25, while scan rows 102, 106, 110 maybe formed on the composite ply 18 within the compaction nip region 25.

By controlling the optical power of the beam 30 (FIGS. 1 and 2), theamount of heating from scan row 100, 102, 104, 106, 108, 110 to scan row100, 102, 104, 106, 108, 110 may be varied. As shown in FIG. 3 withvarying stippling density, scan rows 100, 102, which may be closest tothe nip 24, may be formed using a beam 30 having greater optical powerthan the beam 30 used to form scan rows 104, 106, 108, 110, while scanrows 104, 106 may be formed using a beam 30 having greater optical powerthan the beam 30 used to form scan rows 108, 110. Therefore, greaterheating may be applied to the portions of the composite ply 18 and thesubstrate 22 about to be compacted in the nip 24 (see scan rows 100,102), while the adjacent portions may be gradually preheated (see scanrows 104, 106, 108, 110).

Furthermore, by controlling the pulse frequency of the beam 30 (FIGS. 1and 2) to achieve a non-zero pulse frequency, heat zones 120 and deadzones 122 may be established within the scan rows 100, 102, 104, 106,108, 110. The heat zones 120 correspond to portions of the scan rows100, 102, 104, 106, 108, 110 that received electromagnetic radiation(the on-cycle of the pulse), while the dead zones 122 correspond toportions of the scan rows 100, 102, 104, 106, 108, 110 that did notreceive electromagnetic radiation (the off-cycle of the pulse).

Thus, the waveform shown in FIG. 4A represents the beam 30 (FIGS. 1 and2) that produced scan rows 100, 102, while the waveform shown in FIG. 4Brepresents the beam 30 that produced scan rows 104, 106 and the waveformshown in FIG. 4C represents the beam 30 that produced scan rows 108,110. At this point, those skilled in the art will appreciate thatvariations in the heating profile may be obtained by altering the scanspeed, the optical power of the beam 30 and/or the pulse frequency ofthe beam 30.

Also disclosed is a fiber placement method, which may be used to place acomposite ply on a substrate. Referring to FIG. 5, with additionalreference to FIGS. 1 and 2, one embodiment of the disclosed fiberplacement method, generally designated 200, may begin at Block 202 withthe step of positioning a compaction roller 12 against a substrate 22 toform a nip 24 between the compaction roller 12 and the substrate 22.

At Block 204, a beam 30 of electromagnetic radiation may be scannedproximate the nip 24. The beam 30 may be scanned within a scan field 86,and the scan field 86 may be aligned with (e.g., superimposed over) acompaction nip region 25 proximate the nip 24 between the compactionroller 12 and the substrate 22. For example, the beam 30 may be rasteredacross the scan field 86.

At Block 206, at least one parameter of the beam 30 may be controlled.In one implementation, the optical power of the beam 30 may becontrolled. In another implementation, the pulse frequency of the beam30 may be controlled. In yet another implementation, the both theoptical power of the beam 30 and the pulse frequency of the beam 30 maybe controlled.

At Block 208, a composite ply 18 (e.g., a thermoplastic tow) may bepassed through the nip 24 between the compaction roller 12 and thesubstrate 22. Therefore, the composite ply 18 and/or the substrate 22may be heated by the beam 30 of electromagnetic radiation as it passesthrough the nip 24.

Thus, the disclosed fiber placement method 200 may facilitate controlledradiative heating of a composite ply 18 as the composite ply 18 passesthrough a nip 24. Specifically, by scanning the beam 30 whilecontrolling optical power of the beam and/or pulse frequency of the beam30, the risk of overheating the composite ply 18 and the substrate 22may be significantly reduced (if not eliminated).

Examples of the present disclosure may be described in the context of anaircraft manufacturing and service method 500 as shown in FIG. 6 and anaircraft 600 as shown in FIG. 7. During pre-production, the illustrativemethod 500 may include specification and design, as shown at block 502,of the aircraft 600 and material procurement, as shown at block 504.During production, component and subassembly manufacturing, as shown atblock 506, and system integration, as shown at block 508, of theaircraft 600 may take place. Thereafter, the aircraft 600 may go throughcertification and delivery, as shown block 510, to be placed in service,as shown at block 512. While in service, the aircraft 600 may bescheduled for routine maintenance and service, as shown at block 514.Routine maintenance and service may include modification,reconfiguration, refurbishment, etc. of one or more systems of theaircraft 600.

Each of the processes of illustrative method 500 may be performed orcarried out by a system integrator, a third party, and/or an operator(e.g., a customer). For the purposes of this description, a systemintegrator may include, without limitation, any number of aircraftmanufacturers and major-system subcontractors; a third party mayinclude, without limitation, any number of vendors, subcontractors, andsuppliers; and an operator may be an airline, leasing company, militaryentity, service organization, and so on.

As shown in FIG. 7, the aircraft 600 produced by illustrative method 500(FIG. 6) may include airframe 602 with a plurality of high-level systems604 and interior 606. Examples of high-level systems 604 may include oneor more of propulsion system 608, electrical system 610, hydraulicsystem 612, and environmental system 614. Any number of other systemsmay be included. Although an aerospace example is shown, the principlesdisclosed herein may be applied to other industries, such as theautomotive and marine industries. Accordingly, in addition to theaircraft 600, the principles disclosed herein may apply to othervehicles (e.g., land vehicles, marine vehicles, space vehicles, etc.).

The disclosed fiber placement system and method with modulated laserscan heating may be employed during any one or more of the stages of themanufacturing and service method 500. For example, components orsubassemblies corresponding to component and subassembly manufacturing(block 506) may be fabricated or manufactured using the disclosed fiberplacement system and method with modulated laser scan heating. Also, thedisclosed fiber placement system and method with modulated laser scanheating may be utilized during production stages (blocks 506 and 508),for example, by substantially expediting assembly of or reducing thecost of aircraft 600. Similarly, the disclosed fiber placement systemand method with modulated laser scan heating may be utilized, forexample and without limitation, while aircraft 600 is in service (block512) and/or during the maintenance and service stage (block 514).

Although various embodiments of the disclosed fiber placement system andmethod with modulated laser scan heating have been shown and described,modifications may occur to those skilled in the art upon reading thespecification. The present application includes such modifications andis limited only by the scope of the claims.

What is claimed is:
 1. A method for placing a composite ply on asubstrate comprising: positioning a compaction roller against saidsubstrate to define a nip therebetween; scanning a beam ofelectromagnetic radiation proximate said nip, said beam comprising anoptical power, a pulse frequency and a scan speed; while said beam isbeing scanned, varying at least one of said optical power of said beam,said pulse frequency of said beam and said scan speed of said beam toobtain a desired heating profile proximate said nip; and passing saidcomposite ply through said nip.
 2. The method of claim 1 wherein saidpulse frequency ranges from about 1 kHz to about 10 kHz.
 3. The methodof claim 1 wherein said pulse frequency ranges from about 3 kHz to about6 kHz.
 4. The method of claim 1 wherein said heating profile comprisesgreater heating applied to scan rows closest to said nip than to scanrows further from said nip.
 5. The method of claim 1 wherein saidscanning of said beam comprises sending said beam through a galvoassembly.
 6. The method of claim 1 wherein said beam has a wavelengthranging from about 0.75 μm to about 1.4 μm.
 7. The method of claim 1wherein said composite ply comprises a reinforcement material and athermoplastic polymer.
 8. The method of claim 1 wherein said scanningsaid beam comprises rastering said beam.
 9. The method of claim 1wherein said scanning said beam comprises scanning said beam in a scanrow extending across a scan field.
 10. The method of claim 9 whereinsaid scan row comprises at least one heat zone and at least one deadzone.
 11. The method of claim 9 wherein said scan field extends in anx-axis direction and a y-axis direction, and wherein said scanning saidbeam comprises varying a location of said beam along said x-axisdirection and said y-axis direction.
 12. The method of claim 1 furthercomprising focusing said beam into a spot.
 13. The method of claim 12wherein said scanning said beam comprises moving said spot within a scanfield.
 14. The method of claim 12 wherein said spot has a maximumtransverse dimension ranging from about 0.001 inch to about 1 inch. 15.The method of claim 12 wherein said spot has a maximum transversedimension ranging from about 0.01 inch to about 0.1 inch.
 16. The methodof claim 1 further comprising rotating said compaction roller about anaxis of rotation.
 17. The method of claim 1 wherein said scanning ofsaid beam further comprises sending said beam through an opticalelement.
 18. The method of claim 17 wherein said optical elementcomprises a lens.
 19. The method of claim 5 wherein said galvo assemblyis housed within a scan head, and said method further comprises spacingsaid scan head about 3 inches to about 36 inches away from said nip. 20.The method of claim 19 further comprising optically coupling said scanhead with a laser using an optical fiber.